Surgical gown having adhesive tabs and methods of use

ABSTRACT

A disposable surgical gown having a front closure is provided. The disposable surgical gown comprises a gown body, which includes a first front portion, a back portion, and a second front portion which cooperate to provide the gown body. The gown body also includes a pair of sleeves joined at lateral sides to the gown body. A plurality of adhesive tabs are disposed on the first and second front portions, such that when the surgical gown is donned, the second front portion overlaps the first front portion. Selected adhesive tabs each having a pull tab are configured to permit a wearer to easily grasp each pull tab to set and release the plurality of adhesive tabs to and from the surgical gown.

BACKGROUND

This invention relates to protective attire commonly used in medical orindustrial environments, and so forth. More particularly, this inventionrelates to surgical gowns having an adhesive tab which permits closureof the gown.

As is generally known, sterile surgical gowns are designed to greatlyreduce, if not prevent, the transmission through the gown of liquids andbiological contaminates which may become entrained therein. In surgicalprocedure environments, such liquid sources include the gown wearer'sperspiration, patient liquids such as blood, salvia, perspiration, lifesupport liquids such as plasma and saline, and so forth.

Many surgical gowns were originally made of cotton or linen and weresterilized prior to their use in the operating room. These gowns,however, permitted transmission or “strikethrough” of many of theliquids encountered in surgical procedures. These gowns wereundesirable, if not unsatisfactory, because such “strikethrough”established a direct path for transmission of bacteria and othercontaminates which wick to and from the wearer of the gown. Furthermore,the gowns were costly, and, of course, laundering and sterilizationprocedures were required before reuse.

One use, non-reusable, disposable surgical gowns have largely replacedlinen and/or cotton surgical gowns. Because many surgical proceduresrequire generally a degree of liquid repellency of at least asignificant portion of the gown to prevent strikethrough, disposablegowns for use under these conditions are, for the most part, made fromliquid repellent fabrics, or fabrics having a barrier material in atleast one layer or ply of a multilayer or multiply fabric which isliquid repellant.

Such gowns, however, like their linen counterparts, when worn over othersurgical clothing, can be hot and cause discomfort to the wearer. Inaddition, many gowns are complicated to don or put on, especially in asterile environment, when surgical gowns must be changed periodically asthey become contaminated by liquids, particulate matter, and so forth.

Therefore, there is a need for surgical gowns which have reasonablebarrier properties, and some degree of light weight. In addition, thereis a need for surgical gowns which are easy to put on, and which arereadily adjustable about the girth of a wearer.

Such surgical gowns desirably include lighter weight material which maybe positioned in non-essential areas which are less likely to becontaminated by liquids, particulate matter, and so forth, such as, byway of non-limiting example, the upper sleeves, the back portion, andthe lower front portion of the surgical gown.

Such surgical gowns would desirably be easy for a wearer to put on andtake off before, during and/or after surgical procedures. A surgicalgown which has a closure in the front of the gown is desirable, becauseit is easier for an individual to put on and take off byhimself/herself. Such a surgical gown would desirably include adhesivespots and pull tab locations. Such an adhesive spots and pull tabs woulddesirably provide easy connection and release of the gown to itself, aswell as adjustability of the gown to the individual wearer.

SUMMARY OF THE INVENTION

In response to the difficulties and problems discussed above, adisposable surgical gown having a front closure is provided. Thedisposable surgical gown comprises a gown body, which includes a firstfront portion, a back portion, and a second front portion whichcooperate to provide the gown body. The gown body also includes a pairof sleeves joined at lateral sides to the gown body. A plurality ofadhesive tabs are disposed on the first and second front portions, suchthat when the surgical gown is donned, the second front portion overlapsthe first front portion. Selected adhesive tabs each having a pull tabare configured to permit a wearer to easily grasp each pull tab to setand release the plurality of adhesive tabs to and from the surgicalgown.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic plan view of an outside of the present invention,showing adhesive tab locations on the outside of a surgical gown laidflat in an unworn position before the surgical gown is donned;

FIG. 2 is a schematic plan view of an inside of the surgical gown ofFIG. 1, showing adhesive tab locations the inside of the surgical gownlaid flat in an unworn position before the surgical gown is donned, theadhesive tabs on the inside of the surgical gown cooperating with theadhesive tabs on the outside of the surgical gown to provide a closureto the surgical gown about a wearer when the surgical gown is positionedon a wearer in a worn position;

FIG. 3 is a schematic perspective view of a front side of a wearerdonning the surgical gown;

FIG. 4 is a schematic perspective view of a front side of the surgicalgown of FIGS. 1-3 and the front side of a wearer after donning thesurgical gown, the adhesive tabs on the inside and the outside of thegown providing a closure and a custom fit about the wearer;

FIG. 5 is a sectional view taken along line 4-4, showing a selectedadhesive tab and a pull tab area;

FIG. 6 is schematic perspective view of the surgical gown of FIG. 4,showing a back side of the gown when positioned in a worn position;

FIG. 7 is a schematic plan view of another embodiment of the presentinvention, showing an outside of a surgical gown which is provided asone solid piece, showing the adhesive tabs locations on the outside ofthe surgical gown substantially similar to those shown in FIG. 1; and

FIG. 8 is a schematic plan view of an inside of the surgical gown ofFIG. 7 having adhesive tabs locations on the inside of the surgical gownwhich are substantially similar to those shown in FIG. 2.

DEFINITIONS

As used herein the following terms have the specified meanings, unlessthe context demands a different meaning, or a different meaning isexpressed; also, the singular generally includes the plural, and theplural generally includes the singular unless otherwise indicated.

As used herein, the terms “comprises”, “comprising” and otherderivatives from the root term “comprise” are intended to be open-endedterms that specify the presence of any stated features, elements,integers, steps, or components, but do not preclude the presence oraddition of one or more other features, elements, integers, steps,components, or groups thereof.

As used herein, the terms “fabric” or “material” refers to all woven,knitted and nonwoven fibrous webs, unless one type is specified. Theterms “fabric” or “material” is used broadly herein to mean any planertextile structure produced by interlacing yarns, fibers or filaments.Thus, the fabric can be a woven or nonwoven web, either of which isreadily prepared by methods well-known to those having ordinary skill inthe art. For example, nonwoven webs are prepared by such processes asmeltblowing, coforming, spunbonding, carding, air laying, and wetlaying. Moreover, the fabric can consist of a single layer or multiplelayers. In addition, a multilayered fabric can include films, scrim, andother non-fibrous materials. Desirable materials or fabric(s) aredisclosed, for example, in U.S. Pat. No. 6,037,281 issued to Mathis etal., and in U.S. Pat. No. 5,695,868, issued to McCormick, both of whichare incorporated by reference herein in their entirety.

As used herein, the term “layer” when used in the singular can have thedual meaning of a single element or a plurality of elements.

As used herein the term “meltblown fibers” means fibers formed byextruding a molten thermoplastic material through a plurality of fine,usually circular, die capillaries as molten threads or filaments intoconverging high velocity, usually hot, gas (e.g. air) streams whichattenuate the filaments of molten thermoplastic material to reduce theirdiameter, which may be to microfiber diameter. Thereafter, the meltblownfibers are carried by the high velocity gas stream and are deposited ona collecting surface to form a web of randomly dispersed meltblownfibers. Such a process is disclosed, for example, in U.S. Pat. No.3,849,241 to Butin et al. which is incorporated by reference herein inits entirety. Meltblown fibers are microfibers which may be continuousor discontinuous, are generally smaller than 10 microns in averagediameter, and are generally tacky when deposited onto a collectingsurface.

As used herein “multi-layer laminate” means a laminate wherein some ofthe layers are spunbond and some meltblown such as aspunbond/meltblown/spunbond (SMS) laminate and others as disclosed inU.S. Pat. No. 4,041,203 to Brock et al., U.S. Pat. No. 5,169,706 toCollier, et al., U.S. Pat. No. 5,145,727 to Potts et al., U.S. Pat. No.5,178,931 to Perkins et al. and U.S. Pat. No. 5,188,885 to Timmons etal. each of which are incorporated by reference herein in theirentirety. Such a laminate may be made by sequentially depositing onto amoving forming belt first a spunbond fabric layer, then a meltblownfabric layer and last another spunbond layer and then bonding thelaminate in a manner described below. Alternatively, the fabric layersmay be made individually, collected in rolls, and combined in a separatebonding step. Such fabrics usually have a basis weight of from about 0.1to 12 osy (6 to 400 gsm), or more particularly from about 0.75 to about3 osy. Multi-layer laminates may also have various numbers of meltblown(M) layers or multiple spunbond (S) layers in many differentconfigurations and may include other materials like films (F) or coformmaterials, e.g. SMMS, SM, SFS, SMS etc.

As used herein the terms “bonded” and “bonding” refer to the joining,adhering, connecting, attaching, or the like of two elements. Twoelements will be considered to be bonded together when they are bondeddirectly to one another or indirectly to one another, such as when eachis directly bonded to intermediate elements. Such bonding may occur forexample, by adhesive, thermal or ultrasonic methods.

As used herein the term “thermal point bonding” or “thermal bonding”involves passing a fabric or web of fibers to be bonded between a heatedcalender roll and an anvil roll. When layers of fabric, or two or morefabrics, are thermally bonded, the fabric(s) is/are respectively, heatedto a melting point, such that all pores, capillaries, and so forth, ifany, in the material collapse and/or are sealed in the melting process.The integrity and continuity of the material is maintained (i.e., thematerial does not become too thin or perforated in the bonded areas).

The calender roll is usually, though not always, patterned in some wayso that the entire fabric is not bonded across its entire surface(thermal point bonding), and the anvil roll is usually flat. As aresult, various patterns for calender rolls have been developed forfunctional as well as aesthetic reasons. One example of a pattern haspoints and is the Hansen Pennings or “H&P” pattern with about a 30% bondarea with about 200 bonds/square inch as taught in U.S. Pat. No.3,855,046 to Hansen and Pennings, incorporated herein by reference inits entirety. The H&P pattern has square point or pin bonding areaswherein each pin has a side dimension of 0.038 inches (0.965 mm), aspacing of 0.070 inches (1.778 mm) between pins, and a depth of bondingof 0.023 inches (0.584 mm). The resulting pattern has a bonded area ofabout 29.5%. Another typical point bonding pattern is the expandedHansen Pennings or “EHP” bond pattern which produces a 15% bond areawith a square pin having a side dimension of 0.037 inches (0.94 mm), apin spacing of 0.097 inches (2.464 mm) and a depth of 0.039 inches(0.991 mm). Another typical point bonding pattern designated “714” hassquare pin bonding areas wherein each pin has a side dimension of 0.023inches, a spacing of 0.062 inches (1.575 mm) between pins, and a depthof bonding of 0.033 inches (0.838 mm). The resulting pattern has abonded area of about 15%. Yet another common pattern is the C-Starpattern which has a bond area of about 16.9%. The C-Star pattern has across-directional bar or “corduroy” design interrupted by shootingstars. Other common patterns include a diamond pattern with repeatingand slightly offset diamonds with about a 16% bond area and a wire weavepattern looking as the name suggests, e.g. like a window screen, withabout a 19% bond area. Typically, the percent bonding area varies fromaround 10% to around 30% of the area of the fabric laminate web. As iswell known in the art, the spot bonding holds the laminate layerstogether as well as imparts integrity to each individual layer bybonding filaments and/or fibers within each layer.

As used herein, the term “ultrasonic bonding” or “ultrasonic welding”means a process performed, for example, by passing a fabric, such as anonwoven material, between a sonic horn and anvil roll as illustrated inU.S. Pat. No. 4,374,888 to Bornslaeger, incorporated by reference hereinin its entirety. When layers of fabric, or two or more fabrics, areultrasonically bonded, the fabric(s) is/are respectively, heated to amelting point, such that all pores, capillaries, and so forth, if any,in the material collapse and/or are sealed in the melting process. Theintegrity and continuity of the material is maintained (i.e., thematerial does not become too thin or perforated in the bonded areas).

As used herein, the terms “nonwoven” and “nonwoven fabric” mean either anonwoven web, a film, a foam sheet material, or a combination thereof.

As used herein the terms “fibrous nonwoven” and “fibrous nonwoven fabricor web” mean a web having a structure of individual fibers, filaments orthreads which are interlaid, but not in an identifiable manner as in aknitted fabric. Fibrous nonwoven fabrics or webs have been formed frommany processes such as for example, meltblowing processes, spunbondingprocesses, and bonded carded web processes. The basis weight of fibrousnonwoven fabrics is usually expressed in ounces of material per squareyard (osy) or grams per square meter (gsm) and the fiber diametersuseful are usually expressed in microns. (Note that to convert from osyto gsm, multiply osy by 33.91).

As used herein, the terms “surgical gown” and “protective attire” shallencompass medical garments or medical workwear and other forms ofprotective attire used by various industries/professions to protectworkers from contaminants or to prevent the contamination of others.Such protective attire includes but is not limited to hospital andsurgical gowns, medical scrubs, medical drapes, coveralls, and garmentsused to protect either a portion of, or an entire body. For the purposesof this application, the terms “garment(s)” and “apparel” are usedsynonymously.

As used herein the term “spunbonded fibers” refers to small diameterfibers which are formed by extruding molten thermoplastic material asfilaments from a plurality of fine, usually circular capillaries of aspinneret with the diameter of the extruded filaments then being rapidlyreduced as by, for example, in U.S. Pat. No. 4,340,563 to Appel et al.,U.S. Pat. No. 3,692,618 to Dorschner et al., U.S. Pat. No. 3,802,817 toMatsuki et al., U.S. Pat. Nos. 3,338,992 and 3,341,394 to Kinney, U.S.Pat. No. 3,502,763 to Hartman, and U.S. Pat. No. 3,542,615 to Dobo etal. each of which are incorporated by reference herein in theirentirety. Spunbond fibers are generally not tacky when they aredeposited onto a collecting surface. Spunbond fibers are generallycontinuous and often have average diameters (from a sample of at least10) larger than 7 microns, more particularly, between about 10 and 20microns.

As used herein, the related term “hydrophobic” shall generally refer anonwoven fabric that does not promote the spreading of water. The waterinstead, forms drops and a contact angle that can be measured from theplane of the fiber/material surface, tangent to the water surface at thethree-phase boundary line (air-water-fiber). Typically the contact angleranges from 40-110 degrees, and is often greater than 90 degrees. Thefiber/material also demonstrates a surface tension or energy of lessthan about 50 dynes/cm, such as between about 10-50 dynes/cm. Furtherelaboration on hydrophobic materials may be found in HydrophobicSurfaces, edited by F. M. Fowkes of the Academic Press, New York, 1969,page 1. Hydrophobic fabrics may be produced from materials that areinherently hydrophobic or from hydrophilic fibers/films that have beentreated in some fashion to be hydrophobic. Such treatment may includechemical treatments.

Contact angles can be measured by standard measurement techniques suchas those described in the Introduction to Colloid and Surface Chemistryby Duncan J. Shaw, Third Edition, Butterworths 1980, pages 131-135,incorporated herein by reference. Surface energy of materials can bemeasured using dyne pen sets, such as those available from UV ProcessSupply, Inc., of Chicago, Ill. However, additional methods of measuringsurface energy include Torsion Balance apparatus and other devices,which utilize platinum rings, such as those available from TorsionBalance Supplies of the United Kingdom.

As used herein, the term “wick” or “wicking” shall mean to carrymoisture/liquid away, typically by capillary action. Such term alsoencompasses the ability of a liquid to travel between sheet materials,such as between the surface of a fibrous nonwoven sheet material such asa surgical drape and a film sheet, such as a glove.

As used herein, the term “contaminant” shall mean a chemical agent orbiological organism/pathogen that can potentially harm a human being oranimal.

As used herein, the terms used to describe affixing the various layersor portions of the surgical gown together include “join”, “secure”,“attach” and derivatives and synonyms thereof. Such affixing may beaccomplished by any of several conventional methods. By way of exampleand not limitation, these methods include stitching, gluing, heatsealing, zipping, snapping, ultrasonic or thermal bonding, using a hookand loop fastening system, and other mechanisms and methods familiar tothose skilled in the art. Adhesives suitable for securing the variouslayers of the present invention together include construction adhesivesand pressure sensitive hot-melt adhesives such as Findly H2096 or H2088.Findly adhesives are available from Findly Adhesive Inc. of Wauwatosa,Wis.

As used herein, the term “outer” or “outside” describes that surface ofthe garment or gown which faces away from the wearer when the garment isbeing worn.

As used herein, the term “inner” or “inside” refers to the surface ofthe garment or gown, or part thereof which faces either the clothes orbody of the wearer.

As used herein, the term “particulate matter” refers to a substanceformed of separate particles, i.e., one or more particles.

As used herein, the term “liquid” refers to any liquid, fluid, ormixture of gas and liquid; various types of aerosols and particulatematter may be entrained with such liquids.

These terms may be defined with additional language in the remainingportions of the specification.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to one or more embodiments of theinvention, examples of which are illustrated in the drawings. Eachexample and embodiment is provided by way of explanation of theinvention, and is not meant as a limitation of the invention. Forexample, features illustrated or described as part of one embodiment maybe used with another embodiment to yield still a further embodiment. Itis intended that the invention include these and other modifications andvariations as coming within the scope and spirit of the invention.

Turning now to the drawings and with reference to FIGS. 1-6, protectiveattire or a surgical gown 10 is schematically illustrated. The surgicalgown 10 may be formed from several pieces of fabric or material joinedtogether, as shown in FIGS. 1 and 2. Alternatively, as shown in FIGS. 7and 8, the surgical gown 10 is formed from a single piece or web offabric or material. Different surgical gowns and their method ofmanufacture are disclosed, for example, but not by way of limitation, inU.S. Pat. Nos. 4,214,320, 5,025,501, 6,378,136, and so forth. Thesurgical gown 10 includes a gown body 11 including a first front portion12 configured to cover a portion of the upper front torso of a wearer.The first front portion 12 also substantially covers a lower front torsoand the front of the upper portion of the legs of a wearer. The surgicalgown 10 also includes a back portion 14 which is joined with the firstfront portion 12. The back portion 14 covers the back torso and the backof the upper portion of the legs of a wearer. The surgical gown 10 alsoincludes a second front portion 16 which is joined with the back portion14 of the surgical gown 10, and which, in a worn position, overlaps thefirst front portion 12 of the surgical gown 10, thereby cooperating toprovide a double layer of covering or protection to the front torso andthe upper portion of the front of a wearer's legs. Such doubleprotection is desirable to protect the wearer from liquid and/orparticulate matter. The surgical gown includes a lower end 17 around thelower edge thereof.

The surgical gown 10 is formed by seams 18 which connect or join thefirst front portion 12, the back portion 14, and the second frontportion 16 into the surgical gown 10. The seams 18 join an edge 19 ofthe first front portion 12 to an edge 20 of the back portion 14 and anedge 22 the second front portion 16 to an opposite edge 24 of the backportion 14.

The surgical gown 10 also includes a pair of sleeves 26 which are joinedon each lateral side 28 of the surgical gown 10. Each sleeve 26 isgenerally tubular in configuration, and includes a free end 29. A cuff30 is desirably secured or joined to each free end 29 of each sleeve 26,generally about a wrist opening. Each sleeve 26 may be joined to thesurgical gown 10 at a connected end 32 thereof along seams 18 as well.Alternatively, the sleeves 26 may be joined to the surgical gown 10 atother appropriate locations on the surgical gown 10 (FIGS. 7 and 8).

The surgical gown 10 is configured to provide an adjustable frontclosure. The adjustability of the front closure of the surgical gown 10is provided by a plurality of adhesive tabs 34, and, some selectedadhesive tabs 34 with associated pull tabs 36. The adhesive tabs 34 andpull tabs 36 are generally positioned on the lateral side 28 of thesurgical gown 10 when it is being donned or put on by a wearer. Eachlateral side 28 is defined generally as the area on the gown body 11 ofthe surgical gown itself, as opposed to the sleeves 26, which would lieon or near a lateral side of the wearer, as shown in FIGS. 3 and 4.

The surgical gown 10 includes a neck opening 40 which may provide astraight configuration, as shown in FIGS. 1-4 and 6. Alternatively, theneck opening 40 may be rounded in front, and/or it may be scooped on theback portion 14, generally in a V-shaped or a U-shaped configuration(FIGS. 7 and 8).

Referring to FIGS. 1 and 2, the surgical gown 10 is illustrated in anunworn position showing the inside 41 of the surgical gown 10 (FIG. 2)and the outside 42 of the surgical gown 10 (FIG. 1). The plurality ofadhesive tabs 34, some with associated pull tabs 36, are provideddesirably in specific locations on the surgical gown 10. The adhesivetabs 34 shown herein are illustrated as circular adhesive spots. Theadhesive tabs 34, however, may be provided in any configuration, shapeand/or combination of configuration(s) and shape(s). At least a portionof each adhesive tab 34 may be covered by a release strip 43 (onerelease strip shown partially lifted in FIG. 2 over one adhesive tab 34for illustrative purposes only). Alternatively, the fabric of thesurgical gown 10 may act as both a connecting fabric and a release stripor release fabric.

A pull tab 36 is desirably associated with at least some selectedadhesive tabs 34. The pull tabs 36 are desirably positioned in anon-adhesive area directly adjacent or against the selected adhesive tab34. The selected adhesive tabs 34 are desirably positioned adjacent afree edge 44 of the surgical gown 10, the non-adhesive area adjacent thefree edge 44 provides at least a portion of the pull tab 36. Thisplacement of the pull tabs 36 and their associated selected adhesivetabs 34 permits a wearer to easily grasp and lift and set thenon-adhered pull tab 36 and therefore the adjacent adhesive tab 34 aswell. Therefore, each pull tab 36 is desirably positioned specificallyto permit a wearer to easily lift and grasp the pull tab 36 to releaseone or more adhesive tabs 34 or, alternatively, to set one or moreadhesive tabs 34 in a position or location on the surgical gown 10. Forexample, in the present embodiments, the selected adhesive tabs 34 whichinclude pull tabs 36 include adhesive tabs 34 a, 34 b, 34 c and 34 d.

In addition, at least some of the pull tabs 36 may include “pullindicia” thereon, such as, by way of non-limiting example, the arrow 44on the pull tabs 36 shown in FIGS. 1 and 4. The term “pull indicia” asused herein refers to and includes any word(s) (in any language) and/orany symbol(s) or pictoral representation, and any combination thereof,to indicate to a wearer the location and/or the purpose of the pull tab36 and/or the adhesive tab 34.

In the present embodiment, as shown generally in FIGS. 1-6, the wearerdesirably dons the surgical gown 10 with the inside 41 (FIG. 2)positioned against the wearer, and the outside 42 (FIGS. 1 and 4)positioned away from the wearer. After the wearer places his/her arms inthe sleeves 26, the wearer desirably moves adhesive tab 34 a in adirection 46 (FIG. 2) to adhere to adhesive tab 34 a′, as shownindirectly in FIGS. 3 and 4. This procedure positions the first frontportion 12 of the surgical gown 10 across a portion of the front torsoof the wearer. Then, as illustrated in FIGS. 3 and 4, the wearerpositions the second front portion 16 of the surgical gown in adirection 47 across the front of his/her torso, and adhesively connects,by way of non-limiting example, 34 b with 34 b′, 34 c with 34 c′ and 34d with 34 d′.

In this example, each of the adhesive tabs 34 corresponds to and acts asa landing zone for its corresponding adhesive tab (i.e., adhesive tab 34a to adhesive tab 34 a′). However, this is intended as a non-limitingexample, and it will be appreciated that the adhesive tabs 34 may beadhesively and releasably connected to any area or location on thesurgical gown 10. Therefore, the plurality of adhesive tabs 34 do notrequire a “landing zone” to adhesively connect a portion of the surgicalgown 10 to itself. Further, the position of the plurality of adhesivetabs 34 may vary, so that the position of each adhesive tab 34 is notintended as a limitation of the present invention.

For example, a wearer having a smaller girth may position the surgicalgown more tightly about his/her torso, while a wearer having a largergirth may position the surgical gown more loosely and widely abouthis/her torso. Therefore, some adhesive tabs 34 may be used to adhere toeach other, while other adhesive tabs may be adhered directly to thefabric or material of the surgical gown 10. As a result, the surgicalgown 10 via the adhesive tabs 34 and pull tabs 36 may be adjusted andre-adjusted as necessary about a wearer to promote increased comfort aswell as easy removal, by the wearer lifting the pull tab 36 desirablyassociated with each adhesive tab 34 to release the adhesive tab(s) 34and re-setting the adhesive tab(s) 34 in another position. In thismanner, the plurality of adhesive tabs 34 are easily set on a certainposition or location on the surgical gown 10, which custom fits thesurgical gown 10 to the wearer.

The adhesive may be any adhesive which operates as shown and/ordescribed herein. Desirably, the adhesive is a pressure sensitiveadhesive. Many pressure sensitive adhesives are known in the art and arcommercially available. Alternatively, the adhesive may be a cohesiveadhesive, which only adheres to itself. Many cohesive adhesives areknown in the art and commercially available.

Turning to FIGS. 1 to 8, the basis weight of the surgical gown isdesirably between about 0.5 osy and about 3.0 osy. Certain areas of thesurgical gown may include a fabric having a heavier basis weight. Theseareas of heavier basis weight are desirably in areas or zones 50 mostlikely to be contacted and contaminated by liquids, particulate matter,and the like, during surgery, medical procedures, and so forth. Thesehigh contamination zones 50 may include a lower sleeve portion of thesleeves. Desirably, the fabric in these areas has a basis weight ofabout 1.45 osy to about 3.0 osy. Even more desirably, the fabric inthese areas has a basis weight of about 1.45 osy to about 2.0 osy.Combined in an overlapped configuration, the total basis weight of theoverlapped portions is doubled.

Another high contamination zone 50 is the front torso area of a wearer.This high contamination zone 50, however, may be addressed by thecombination of the first and second front portions 12, 16, which overlapeach other. Therefore, in this high contamination zone 50, sinceportions of the gown are overlapped for protection, the basis weight ofeach layer may each be less, that is, a lighter basis weight. Desirably,the fabric in these areas has a basis weight of about 0.5 osy to about1.44 osy. Even more desirably, the fabric in these areas has a basisweight of about 0.5 osy to about 1.3 osy. Combined in an overlappedconfiguration, the total basis weight of the overlapped portions isdoubled (i.e., from about 1.0 osy to about 2.88 osy).

However, certain low contamination areas or zones 54 of the surgicalgown 10 may include a fabric having a lighter basis weight, in which thesurgical gown 10 does not overlap itself. These low contamination zones54 of lighter basis weight allow the surgical gown 10 to be cooler andmore comfortable to a wearer. These zones are less likely to becontacted and contaminated by one or more liquids, particulate matter,and so forth during procedures, such as surgery. These low contaminationzones 54 desirably include an upper sleeve portion of the sleeves 26,and the back portion 14. Desirably, the fabric in these areas has abasis weight of about 0.5 osy to about 1.44 osy. Even more desirably,the fabric in these areas has a basis weight of about 0.5 osy to about1.3 osy. Lower basis weight permits the gown to be constructed lessexpensively.

Alternatively, the surgical gown 10 may utilize the same basis weightthroughout. In this instance, the basis weight desirably is between 0.5osy and about 3.0 osy. Such a basis weight may be used in both highcontamination zones and low contamination zones, although it will beappreciated that the basis weight in a particular area will increase ifthe fabric of the surgical gown 10 is overlapped in that area.

The double layer of protection provided by the first and second frontportions 12, 16 provides light weight with the added protection of twolayers against the insult of liquid and/or particulate matter. Thesingle layer of the back portion 14 provides coolness to the wearer. Thefront opening and closure of the surgical gown 10, along with the use ofadhesive tabs 34 and pull tabs 36, permits quick and easy donning by thewearer alone. Such front opening and closure is intended asnon-limiting, and it will be appreciated that the surgical gown 10 shownand described herein may be reversed to be adapted to be donned from therear, with some assistance.

The present invention is desirably used with an improved cloth-like,liquid-impervious, breathable barrier material, such as that disclosedin U.S. Pat. No. 6,037,281, which is incorporated in its entiretyherein, and which is discussed below in detail herein. The breathablebarrier material possesses a unique balance of performancecharacteristics and features making the material suitable for use informing surgical articles, as well as other garment and over-garmentapplications, such as personal protective equipment applications. Thebarrier material is a laminate comprising three layers—a top nonwovenlayer formed, for example, of spunbond filaments, a bottom nonwovenlayer formed, for example, of spunbond filaments, and a middlebreathable film layer formed, for example, of a microporous film. Theindividual layers of barrier material are laminated, bonded or attachedtogether by known means, including thermal-mechanical bonding,ultrasonic bonding, adhesives, and the like. As used herein, the terms“layer” or “web” when used in the singular can have the dual meaning ofa single element or a plurality of elements. In anther alternative, thematerial is a nonwoven material of any type known in the art having afilm or polymer layer or coating. Such a film or polymer layer orcoating is desirably provided in a range of about 0.5 mils to about 3.0mils.

Commercially available thermoplastic polymeric materials can beadvantageously employed in making the fibers or filaments from which thetop and bottom layers are formed. As used herein, the term “polymer”shall include, but is not limited to, homopolymer, copolymers, such as,for example, block, graft, random and alternating copolymers,terpolymers, etc., and blends and modifications thereof. Moreover,unless otherwise specifically limited, the term “polymer” shall includeall possible geometric configurations of the material, including,without limitation, isotactic, syndiotactic, random and atacticsymmetries. As used herein, the terms “thermoplastic polymer” or“thermoplastic polymeric material” refer to a long-chain polymer thatsoftens when exposed to heat and returns to the solid state when cooledto ambient temperature. Exemplary thermoplastic materials include,without limitation, polyvinyl chlorides, polyesters, polyamides,polyfluorocarbons, poly-olefins, polyurethanes, polystyrenes, polyvinylalcohols, caprolactams, and copolymers of the foregoing.

Nonwoven webs that can be employed as the nonwoven top and bottom layerscan be formed by a variety of known forming processes, includingspunbonding, airlaying, meltblowing, or bonded carded web formationprocesses. For example, the top layer and bottom layer are both spunbondnonwoven webs, which have been found advantageous in forming barriermaterial. Spunbond nonwoven webs are made from melt-spun filaments. Themelt-spun filaments are deposited in a substantially random manner ontoa moving carrier belt or the like to form a web of substantiallycontinuous and randomly arranged, melt-spun filaments. Spunbondfilaments generally are not tacky when they are deposited onto thecollecting surface. The melt-spun filaments formed by the spunbondprocess are generally continuous and have average diameters larger than7 microns based upon at least 5 measurements, and more particularly,between about 10 and 100 microns. Another frequently used expression offiber or filament diameter is denier, which is defined as grams per 9000meters of a fiber or filament.

Spunbond webs generally are stabilized or consolidated (pre-bonded) insome manner immediately as they are produced in order to give the websufficient integrity and strength to withstand the rigors of furtherprocessing. This pre-bonding step may be accomplished through the use ofan adhesive applied to the filaments as a liquid or powder which may beheat activated, or more commonly, by an air knife or compaction rolls.As used herein, the term “compaction rolls” means a set of rollers aboveand below the nonwoven web used to compact the web as a way of treatinga just produced, melt-spun filament, particularly spunbond, web, inorder to give the web sufficient integrity for further processing, butnot the relatively strong bonding of later applied, secondary bondingprocesses, such as through-air bonding, thermal bonding, ultrasonicbonding and the like. Compaction rolls slightly squeeze the web in orderto increase its self-adherence and thereby its integrity. An air knife,as its name implies, directs heated air through a slot or row ofopenings onto the web to compact and provide initial bonding.

An exemplary secondary bonding process utilizes a patterned rollerarrangement for thermally bonding the spunbond web. The rollerarrangement typically includes a patterned bonding roll and a smoothanvil roll which together define a thermal patterning bonding nip.Alternatively, the anvil roll may also bear a bonding pattern on itsouter surface. The pattern roll is heated to a suitable bondingtemperature by conventional heating means and is rotated by conventionaldrive means, so that when the spunbond web passes through the nip, aseries of thermal pattern bonds is formed. Nip pressure within the nipshould be sufficient to achieve the desired degree of bonding of theweb, given the line speed, bonding temperature and materials forming theweb. Percent bond areas within the range of from about 10 percent toabout 20 percent are typical for such spunbond webs.

The middle breathable film layer can be formed of any microporous filmthat can be suitably bonded or attached to top and bottom layers toyield a barrier material having the unique combination of performancecharacteristics and features described herein. A suitable class of filmmaterials includes at least two basic components: a thermoplasticelastomeric polyolefin polymer and a filler. These (and other)components can be mixed together, heated and then extruded into amono-layer or multi-layer film using any one of a variety offilm-producing processes known to those of ordinary skill in the filmprocessing art. Such film-making processes include, for example, castembossed, chill and flat cast, and blown film processes.

Generally, on a dry weight basis, based on the total weight of the film,the middle breathable film layer will include from about 30 to about 60weight percent of the thermoplastic polyolefin polymer, or blendthereof, and from about 40 to about 70 percent filler. Other additivesand ingredients may be added to the film layer 14 provided they do notsignificantly interfere with the ability of the film layer to functionin accordance with the teachings of the present invention. Suchadditives and ingredients can include, for example, antioxidants,stabilizers, and pigments.

In addition to the polyolefin polymer, the middle breathable film layeralso includes a filler. As used herein, a “filler” is meant to includeparticulates and other forms of materials which can be added to the filmpolymer extrusion blend and which will not chemically interfere with theextruded film but which are able to be uniformly dispersed throughoutthe film. Generally, the fillers will be in particulate form and mayhave a spherical or non-spherical shape with average particle sizes inthe range of about 0.1 to about 7 microns. Both organic and inorganicfillers are contemplated to be within the scope of the present inventionprovided that they do not interfere with the film formation process, orthe ability of the film layer to function in accordance with theteachings of the present invention. Examples of suitable fillers includecalcium carbonate (CaCO3), various kinds of clay, silica (SiO2),alumina, barium carbonate, sodium carbonate, magnesium carbonate, talc,barium sulfate, magnesium sulfate, aluminum sulfate, titanium dioxide(TiO2), zeolites, cellulose-type powders, kaolin, mica, carbon, calciumoxide, magnesium oxide, aluminum hydroxide, pulp powder, wood powder,cellulose derivatives, chitin and chitin derivatives. A suitablecoating, such as, for example, stearic acid, may also be applied to thefiller particles.

As mentioned herein, the breathable film layer may be formed using anyone of the conventional processes known to those familiar with filmformation. The polyolefin polymer and filler are mixed in appropriateproportions given the ranges outlined herein and then heated andextruded into a film. In order to provide uniform breathability asreflected by the water vapor transmission rate of the film, the fillershould be uniformly dispersed through-out the polymer blend and,consequently, throughout the film layer itself so that upon stretchingpores are created to provide breathability. For purposes of the presentinvention, a film is considered “breathable” if it has a water vaportransmission rate of at least 300 grams per square meter per 24 hours(g/m2/24 hours), as calculated using the test method described herein.Generally, once the film is formed, it will have a weight per unit areaof less than about 80 grams per square meter (gsm) and after stretchingand thinning, its weight per unit area will be from about 10 gsm toabout 25 gsm.

The breathable film layer used in the example of the present inventiondescribed below is a mono-layer film, however, other types, such asmulti-layer films, are also considered to be within the scope of thepresent invention provided the forming technique is compatible withfilled films. The film as initially formed generally is thicker andnoisier than desired, as it tends to make a “rattling” sound whenshaken. Moreover, the film does not have a sufficient degree ofbreathability as measured by its water vapor transmission rate.Consequently, the film is heated to a temperature equal to or less thanabout 5 degrees C. below the melting point of the polyolefin polymer andthen stretched using an in-line machine direction orientation (MDO) unitto at least about two times (2×) its original length to thin the filmand render it porous. Further stretching of the middle breathable filmlayer, to about three times (3×), four times (4×), or more, its originallength is expressly contemplated in connection with forming middlebreathable film layer. After being stretch-thinned, the middlebreathable film layer should have an “effective” film gauge or thicknessof from about 0.2 mil to about 0.6 mil. The effective gauge is used totake into consideration the voids or air spaces in breathable filmlayers.

Cuffs 30, as illustrated best in FIGS. 3, 4 and 6, are desirablyattached to the sleeves 26 of the surgical gown 10, and may also beattached at the neck of each garment, and so forth (not shown). Suchcuffs 30 are desirably made from elastic yarns formed from synthetic ornatural materials. An example of a synthetic material for forming theelastic yarns is polyurethane. Spandex is an example ofpolyurethane-based elastomer. More particularly, spandex is apolyurethane in fiber form containing a thermoplastic polyurethaneelastomer with at least 85% polyurethane content. Commercial examples ofspandex include LYCRA, VYRENE, DORLASTAN, SPANZELLE and GLOSPAN. Anexample of a natural material for forming elastic yarns is naturalrubber. Polyester, nylon, and combinations of any of the foregoingsynthetic and/or natural elastic yarns may also be used. The use ofthese, and other materials to construct sleeves and/or cuffs isdisclosed in U.S. Pat. No. 5,594,955, which is incorporated by referencein its entirety herein. In the present embodiment, the cuffs 30 aredesirably sewn, thermally bonded, ultrasonically bonded, adhesivelyattached, and so forth to the free end 29 of each sleeve 26.

For all embodiments shown and/or described herein, desirably, asillustrated in FIG. 5, the adhesive on a portion of each of theplurality of adhesive tabs 34 has strong shear and friction propertiesin an area 70. Desirably, the peels strength in the area 70 issufficiently strong or adhesive so that the adhesive tabs 34 hold thesurgical gown 10 securely in the worn position. If the adhesive tabs areis removed after its initial application, it will be understood thatthis removal results in deformation of the fabric or material of thesurgical gown 10. In addition, the for all embodiments shown and/ordescribed herein, desirably the adhesive on a portion of the adhesivetabs 34 near the pull tab 36 has a week peal strength in an area 72.Desirably, the peel strength in an area 72 is less strong than that inthe area 70, so that at least a portion of the adhesive tabs 34 can beeasily lifted, to facilitate adjustment of the fit of the surgical gown10 to a user, or to permit removal of the surgical gown 10.

In another embodiment of the present invention, illustrated by FIGS. 7and 8, an alternative surgical gown 110 is schematically illustrated.The surgical gown 110 is substantially similar to the surgical gown 10,except that it is formed from a blank of fabric or material about a formsuch that it does not include any seams. In addition, the surgical gown110 may include a “scooped” or lowered neck opening 140 on the backportion 14. Such a scooped neck opening 114 may be provided in aV-shaped, a U-shaped, or other configuration which permits heat from awearer's neck and upper back to escape, providing increased coolness andcomfort. It will be appreciated that the surgical gown 110 may be donnedor put on and taken off by a wearer in the same manner is thatpreviously shown and described in detail herein. In addition, thesurgical gowns 10 and 110 may include any feature or characteristicshown and/or described herein.

While the present invention has been described in connection withcertain preferred embodiments it is to be understood that the subjectmatter encompassed by way of the present invention is not to be limitedto those specific embodiments. On the contrary, it is intended for thesubject matter of the invention to include all alternatives,modifications and equivalents as can be included within the spirit andscope of the following claims.

1. A disposable surgical gown having a front closure, the disposablesurgical gown comprising: a gown body comprising a first front portion,a back portion, and a second front portion which cooperate to providethe gown body, a pair of sleeves joined at lateral sides to the gownbody, and a plurality of adhesive tabs which are disposed on the firstand second front portions, such that when the surgical gown is donned,the second front portion overlaps the first front portion, selectedadhesive tabs each having a pull tab configured to permit a wearer toeasily grasp the pull tab to set and release the plurality of adhesivetabs to and from the surgical gown.
 2. The disposable surgical gown ofclaim 1, wherein seams connect the first and second front portions tothe back portion.
 3. The disposable surgical gown of claim 1, whereinthe gown is formed without seams.
 4. The disposable surgical gown ofclaim 1, wherein the adhesive includes a pressure sensitive adhesive. 5.The disposable surgical gown of claim 1, wherein each adhesive tabrequires no landing area for adhesion to and release from the surgicalgown.
 6. The disposable surgical gown of claim 5, wherein the gown bodyincludes at least one adhesive tab on an inside and one an adhesive tabon an outside of the gown body.
 7. The disposable surgical gown of claim1, wherein the pull tab is formed adjacent a free edge of the gown body.8. The disposable surgical gown of claim 1, wherein the pull tabincludes a non-adhesive area adjacent an adhesive which is configured tobe easily grasped by a wearer.
 9. The disposable surgical gown of claim8, wherein one of the gown and the pull tab includes pull indicia. 10.The disposable surgical gown of claim 1, wherein at least a portion ofthe adhesive on the adhesive tab is protected prior to use by a releasestrip positioned over the adhesive.
 11. The disposable surgical gown ofclaim 1, wherein the basis weight for surgical gown is in a range ofabout 0.5 osy to about 3.0 osy.
 12. The disposable surgical gown ofclaim 11, wherein the basis weight for the surgical gown varies betweenhigh contamination zones and low contaminated zones.
 13. The disposablesurgical gown of claim 12, wherein the first and second front portionsand a lower portion of the sleeves provide high contamination zones. 14.The disposable surgical gown of claim 13, wherein the basis weight ofthe sleeves in the high contamination zones is in a range of about 1.45osy to about 3.0 osy.
 15. The disposable surgical gown of claim 13,wherein the basis weight of the first and second front portions are eachabout 0.5 osy to about 1.44 osy.
 16. The disposable surgical gown ofclaim 12, wherein the an upper portion of the sleeves and the backportion are included in low contamination zones.
 17. The disposablesurgical gown of claim 16, wherein the basis weight of the fabric in thelow contamination zones is about 0.5 osy to about 1.44 osy.
 18. Thedisposable surgical gown of claim 1, wherein the back portion isconfigured to provide a scooped opening near a wearer's neck and upperback.
 19. The disposable surgical gown of claim 18, wherein the scoopedopening is one of V-shaped and U shaped.
 20. A disposable surgical gownhaving a front closure, the disposable surgical gown comprising: a gownbody comprising a first front portion, a back portion, and a secondfront portion, the gown body including a pair of sleeves joined atlateral sides to the gown body, at least the first and second frontportions and the back portion formed from a material having a lowerbasis weight relative to a basis weight of a material forming a lowerportion of the pair of sleeves, the gown body including a plurality ofadhesive tabs which are disposed on the first and second front portions,such that when the surgical gown is donned, the second front portionoverlaps the first front portion, selected adhesive tabs each having apull tab configured to permit a wearer to easily grasp the pull tab toset and release the plurality of adhesive tabs to and from the surgicalgown.
 21. The disposable surgical gown of claim 20, wherein seamsconnect the first and second front portions to the back portion.
 22. Thedisposable surgical gown of claim 20, wherein the gown is formed withoutseams.
 23. The disposable surgical gown of claim 20, wherein theadhesive includes a pressure sensitive adhesive.
 24. The disposablesurgical gown of claim 20, wherein each adhesive tab requires no landingarea for adhesion to and release from the surgical gown.
 25. Thedisposable surgical gown of claim 24, wherein the gown body includes atleast one adhesive tab on an inside and one an adhesive tab on anoutside of the gown body.
 26. The disposable surgical gown of claim 20,wherein the pull tab is formed adjacent a free edge of the gown body.27. The disposable surgical gown of claim 20, wherein the pull tabincludes a non-adhesive area adjacent an adhesive which is configured tobe easily grasped by a wearer.
 28. The disposable surgical gown of claim27, wherein one of the gown and the pull tab includes pull indicia. 29.The disposable surgical gown of claim 20, wherein at least a portion ofthe adhesive on the adhesive tab is protected prior to use by a releasestrip positioned over the adhesive.
 30. The disposable surgical gown ofclaim 20, wherein the basis weight for surgical gown is in a range ofabout 0.5 osy to about 3.0 osy.
 31. The disposable surgical gown ofclaim 30, wherein the basis weight for the surgical gown varies betweenhigh contamination zones and low contaminated zones.
 32. The disposablesurgical gown of claim 31, wherein the first and second front portionsand a lower portion of the sleeves provide high contamination zones. 33.The disposable surgical gown of claim 32, wherein the basis weight ofthe sleeves in the high contamination zones is in a range of about 1.45osy to about 3.0 osy.
 34. The disposable surgical gown of claim 32,wherein the basis weight of the first and second front portions are eachabout 0.5 osy to about 1.44 osy.
 35. The disposable surgical gown ofclaim 32, wherein the an upper portion of the sleeves, and the backportion are included in low contamination zones.
 36. The disposablesurgical gown of claim 35, wherein the basis weight of the fabric in thelow contamination zones is about 0.5 osy to about 1.44 osy.
 37. Thedisposable surgical gown of claim 1, wherein the back portion isconfigured to provide a scooped opening near a wearer's neck and upperback.
 38. The disposable surgical gown of claim 37, wherein the scoopedopening is one of V-shaped and U shaped.
 39. A disposable surgical gownhaving a front closure, the disposable surgical gown comprising: a gownbody comprising a first front portion, a back portion, and a secondfront portion cooperating to provide the gown body, the gown bodyincluding a pair of sleeves joined at lateral sides to the gown body, ahigh contamination zone provided by a lower portion of the sleeves andthe first and second front portions when overlapped in a worn position,a low contamination zone provided by the back portion and an upperportion of the sleeves when in a worn position, the gown body includinga plurality of adhesive tabs which are disposed on the first and secondfront portions such that when the surgical gown is donned, the secondfront portion overlaps the first front portion, selected adhesive tabseach having a pull tab configured to permit a wearer to easily grasp thepull tab to set and release the plurality of adhesive tabs to and fromthe surgical gown.